Conductive Structure with Segmented Single and Multi-Layer Busbars

Solution Overview

Problem

Existing conductive structures in vehicles lack an optimal configuration for providing a flexible and rigid conductive path that balances installation workability and handling, particularly in vehicles requiring power and signal transmission.

Innovation Solution

A conductive structure comprising a single-layer busbar with high rigidity for route regulation and a multi-layer busbar with high flexibility for deformation allowance, where the multi-layer busbar is laminated with conductive thin plates and attached to the single-layer busbar, allowing mutual contact and insulation, enabling a balanced flexibility and rigidity for effective installation and transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a single-layer busbar is used for the entire conductive path, then the installation route can be regulated with high rigidity, but the conductive structure loses flexibility and ability to allow deformation

Engineering Contradiction:

Improveroute regulation capabilityVSAvoidflexibility and deformation allowance

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The conductive structure is divided into two distinct segments: a single-layer busbar portion for route regulation and a multi-layer busbar portion for flexibility. This segmentation allows each segment to perform its specific function optimally without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the conductive structure are given different structural qualities - the single-layer portion provides rigidity where route regulation is needed, while the multi-layer portion provides flexibility where deformation allowance is required. This local differentiation resolves the contradiction between overall rigidity and flexibility.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If a multi-layer busbar is used for the entire conductive path, then flexibility and deformation allowance are improved, but the ability to regulate installation route is reduced due to lower rigidity

Engineering Contradiction:

Improveflexibility and deformation allowanceVSAvoidroute regulation capability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The conductive structure is divided into two distinct segments: a single-layer busbar portion for route regulation and a multi-layer busbar portion for flexibility. This segmentation allows each segment to perform its specific function optimally without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the conductive structure are given different structural qualities - the single-layer portion provides rigidity where route regulation is needed, while the multi-layer portion provides flexibility where deformation allowance is required. This local differentiation resolves the contradiction between overall rigidity and flexibility.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the laminated busbars are capable of mutual displacement, then flexibility is improved, but the attachment end stability and electrical connection reliability deteriorate

Engineering Contradiction:

ImproveflexibilityVSAvoidattachment end stability and electrical connection

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The multi-layer busbar is segmented into a main body portion where layers can displace relative to each other (providing flexibility) and an attachment end portion where layers are fixed together (providing stability). This spatial segmentation resolves the contradiction between flexibility and attachment stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The attachment end is designed with preliminary fixed positioning of the laminated busbars before they reach the attachment point. This preliminary action ensures that when electrical connections are made, the busbars are already in a stable, fixed state, preventing displacement during connection and ensuring reliable electrical contact.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3925834B1Conductive structure

Publication Date: 2023.07.05 YAZAKI CORP

Figure 1
Figure 2~3

AI summary

A conductive structure (1) includes: a single-layer busbar (10) that is formed in a plate shape and constitutes a conductive path (100); and a multi-layer busbar (20) that is configured by laminating a plurality of busbars which are formed as plates thinner than the single-layer busbar (10) and that is joined to an end of the single-layer busbar (10) and constitutes the conductive path (100). The multi-layer busbar (20) includes a main body portion (20A) in which at least some of the laminated plurality of busbars are capable of mutual displacement relative to the busbars adjacent thereto, and a joining end (20B) located at an end of the main body portion (20A) on the single-layer busbar (10) side and in which the laminated plurality of busbars are incapable of mutual displacement relative to each other, the joining end (20B) being joined to the end of the single-layer busbar (10).